864257 Volvo.Penta Tube, l=108mm

1. Disconnect the radiator hose from elbow (3).2. Remove two tube assemblies (2).3. Remove the bolts that hold elbow (3) to the water pump, and remove the elbow.4. Remove the bolts that hold elbow (1) to the water pump.5. Remove the bolts and retainers that hold elbow (1) to the tube assembly, and remove the elbow. 6. Remove the bolts and adapter assembly (4) from the front drive housing. 7. Remove O-ring seals (6) and (7) from adapter assembly (4).8. If necessary, remove bearing (5) from the adapter assembly. 9. Fasten a hoist and tooling (A) to water pump (8). Remove the bolts and the water pump from the front drive housing. The weight of the water pump is 25 kg (55 lb).10. Remove O-ring seal (9) from the water pump. The following steps are for installation of the Auxiliary Water Pump.11. Put O-ring seal (9) in position on the water pump. Put clean engine oil on the O-ring seal.12. Fasten a hoist and tooling (A) to water pump (8). Put the water pump in position on the front drive housing, and install the bolts that hold it. 13. If the bearing was removed from adapter assembly (4), align the hole in the bearing with the oil hole in the adapter assembly. Install the bearing with a press and tool (B). Install the bearing until it is 1.5 0.5 mm (.06 .02 in) below surface (X). The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 .0022 in) after installation. 14. Put O-ring seals (6) and (7) in position on adapter assembly (4). Put clean oil on the O-ring seals.15. Put the adapter assembly in position on the front drive housing, and install the bolts that hold it. 16. Make sure the O-ring seal is in position on tube assembly (10). Put elbow (1) in position on the tube assembly, and install the retainers and bolts to hold it in place.17. Put the gasket in position between elbow (11) and the water pump, and install the bolts and nuts that hold the elbow to the water pump.18. Put the O-ring seal in position on the back of the water pump, and install elbow (3).19. Install two tube assemblies (2).20. Connect the radiator hose to elbow (3).End By:a. install air compressorDisassemble Auxiliary Water Pump
Start By:a. remove auxiliary water pump 1. Remove O-ring seals (3) and (4) from the pump housing.2. Remove the bolts and gear (2) from shaft (1). 3. Remove the bolts and adapter (5) from the pump housing. Remove the O-ring seal from adapter (5). 4. Loosen bolt (6) and the washer that hold impeller (7) to the shaft5. Use tooling (A) to loosen impeller (7) from the end of the pump shaft Remove tooling (A), bolt (6), the washer and impeller (7) from the pump shaft and housing. 6. Remove spring (9) from carbon seal assembly (10). Remove carbon seal assembly (10) from the end of shaft (8). 7. Remove the bolts that hold retainer washers (12) to the pump housing. Remove shaft (1) and washers (12) from the pump housing. 8. Remove the bolts that hold the shims and retainer washers (13) to the pump housing. Remove shaft (8), the shims and washers (13) from the pump housing.9. Remove the rubber ring and ceramic seal (11) from the pump housing. 10. Remove lip-type seal (14) from the pump housing. 11. Remove bearing (15) from the pump housing.Assemble Auxiliary Water Pump
1. Make sure the oil hole in the bearing is in alignment with the oil passage in housing (1). Use tool group (A) and a press to push the bearing in housing (1) until it is 1.5 0.5 mm (.06 .02 in) below the surface of housing (1). The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 .0022 in). 2. Use tool group (A) to install the lip-type seal in housing (1). Make sure the lip of the seal is toward the bearing. Put clean engine oil on the lip of the seal. 3. Install shaft (2) in the pump housing. Install retainer washers (3), the shims and bolts to hold shaft (2) in the pump housing. 4. Put clean engine oil on the bearing in the pump housing, and install shaft (4) and retainer washers (5) over shaft (2). Install the bolts to hold retainer washers (5) to the pump housing.
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surfaces of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
5. Install ceramic seal ring (6) in the rubber seal. Put clean water on the rubber seal and ceramic seal ring for lubrication. Use hand pressure and the tool (which is with the replacement seal group) to install the seal and seal ring as shown. 6. Remove the spring from carbon seal assembly (7). Put clean water on the inside diameter of the seal assembly for lubrication. Use hand pressure and the tool (which is with the replacement seal group) to push seal assembly (7) on the shaft until seal faces make light contact. 7. Install spring (8) on carbon seal assembly (7). 8. Put impeller (9) in position on the pump shaft as shown. 9. Install the bolt and washer that hold impeller (9) to the pump shaft Tighten the bolt to a torque of 38 4 N m (28 3 lbft). 10. Install O-ring seal (11) around adapter (10), and put a small amount of clean engine oil or glycerine on it.11. Put adapter (10) in position, and install the bolts to hold it to the pump housing. 12. Put gear (12) in position on shaft (4), and install the bolts to hold gear (12). 13. Install O-ring seals (13) and (14) in the pump housing, and put clean engine oil on the